Thick butt shingle



Aug. 29, 1939. c. R. ECKERT THICK BUTT SHINGLE' Original Filed Aug. 14, 1926 INVENTOR C/are/rce 5: Etierf Patented Aug. 29', 1939 PATENT OFFICE 2,171,143 'rrncx BUTT SHINGLE Clarence It. Eckert,

Englewood, N. J., assignor, by

mesne assignments, to The Patent and Licensing Corporation, New York, N. Y., a corporation of Massachusetts Original application August 14, 1926, Serial No.

Divided and this application October 28, 1931, Serial No. 571,543

2 Claims.

This invention relates to a thick butt shingle element, and more particularly, to a thick butt strip shingle having tabs disposed along one longitudinal edge of the body portion thereof. This application is a division of application Serial No. 129,132, filed August 14, 1926, issued as Patent No. 1,842,448, claiming the process for making the product claimed herein.

Thick butt shingle elements have heretofore been made chiefly by hand-dipping a granular surfaced coated felt base into a bath of molten asphalt or other bituminous material, the element then being allowed to drain and thereafter being surfaced with granular material. This is an expensive and unsatisfactory manner of producing thick butt shingles involving time-consuming 'hand labor and waste of asphalt occasioned by the dipping operation.

In applicant's prior application, Serial No. 129,132, hereinabove referred to, a continuous process of making thick butt shingles is disclosed and claimed. This application 'is directed to the novel thick butt shingle resulting from the practice of this process. This thick butt shingle differs from the product made by hand-dipping in the following important respects:

(1) The coating applied to the granular surfaced base is of uniform thickness as distin guished from the tapering thickness of the coating applied by the dipping operation due to the draining of the molten asphalt coating and the' gradual hardening of the coating as it drains and flows down along the shingle element.

(2 The coating'applied to the granular surfaced base extends about theface of the tabs and seals the edges without covering the rear surface .of the tabs, which is necessarily covered in a clipping operation.

Thus, a savingof coating material equivalent to that used to coat the rear surface of the tab portions is effected in the manufacture of the shingle of this invention and at the same time all exposed. portions of the element are'eflectively v sealedand protected against weathering,

In the accompanying drawing, in which like reference characters refer to like parts- Fig. 1 is a diagrammatic side elevation, par-' tially in section, of the type of apparatus which I havefound satisfactory for carrying out my invention;

Fig. 2 is a digramm'atic plan view ofthe web as it travels through the apparatus;

Fig. 3 is a cross section of the apparatus which may be employed for the application of the butt thickening coating to the strips;

Fig. 4 is a plan view thereof; 7

Fig. 5 is a section, taken through one of the tabs, of thethick butt shingle of my invention.

Referring now to the drawing, a web A of roofing felt of the desired width is led through the 5 saturating tank 5, where it may be impregnated with a suitable waterproofing compound, such as asphalt, or tar,-and,passes between the squeeze rolls 6 for removing excess saturant after which the web may pass over drying racks l for allow- 10 ing the saturated web to cool somewhat. The web is then fed through the coating rolls 8 and 9, by means of which a relatively thin coat of weatherproofing compound, such as tar or asphalt (usually of a'higher melting point than that ofthe saturant), is applied to the impregnated sheet. While the coating is still soft, the web passes under the hoppers H and I2 and around the rolls l3 and I4. I

The hoppers H and 12 are of usual design, hopper ll containing crushed coarse particles 'of slate, or other wear-resistant granular material, of any suitable color or mixture of colors which may be showered upon the face of the coated web, thus surfacing the web. Hopper g5 12 contains mica dust which is fed to the rear surface of the web as it passes about roller l3, thus rendering the rear surface of the web noncementitious.

The web now passes over the cooling rolls I5 and I6 and over the idler roll I! and between the platen roll l8 and the cutting roll l9. By the installation of the desired cutting roll the finished shingle element may be made to take the form of a strip having rectangular tabs, or hexagonal tabs, or octagonal tabs or other desired shape. Such cutting practice is, in general, known to those skilled in-the art, and it is thought, need not be dealt with more specifically here. After passing the cutting roll, the web A will appear as a plurality of strips 1, 2, 3, and 4. These strips pass through the tab knocker 20 and splitter assembly 2| which, in the case of the type of shingle strip shown, removes the cut outs and splits the almost severed web into shingle simulating tabs. (The specific details of this assembly are described and claimed in U. S. Patent No. 1,744,473.) By means of the conveyor belts 22 and 23, strips 1 and 3 travel in a downward direction, while strips 2 and [travel in an upward direction. Obviously, if octagonal or hexagonal shingles are being produced certain portions of the tab knocker and stripper assembly, such as the tab knocker itself, would be omitted.

strips having The strips I, 2, 3 and l are. now ready to have applied thereto the tab or butt thickening coating of weather-resisting compound such as asphalt, tar, or other bituminous material. This is prefe copending application Serial No. 129,132, .in which case a shingle having the'weather face and also the rear face ofthe tabs each provided with a double coating of bituminous material which may be surfaced with granular material would result. 7

The coating apparatus of Figs. ,3 and {involves a coating material tank 33 arranged to feed the coating material to 'a coating roll 36 having an enlarged portion 35 thereon. The flow of coating material from tank 33 upon .the enlarged portion 35 of roll 36 is controlled by means of 'a gate 35. Enlarged portion 35 of. roll 36 applies the coating to the upper side of the "tabs and to the edge thereof while the strips are supported on plates 6B,'the coating material being supplied. to the portion of roll 34! slightly in excess of that needed to coat the upper surface of the tabs so that sufiicle'nt coating material will run over the edges of the tabs-to coat them; thus, the face of the tabs and thecut edges thereof are completely covered with bituminous coating material. It will be noted that the coating material is applied to the top ofthe strip and flows down over the cut edges thereof, hardening on theedges and eifectively sealing them. Thus, the coating applied to the top of each element is in effect extended over the forward edge and the sides of the tabs forming a continuous protective layer covering the face of the tab portions only and sealing all cut edges of the shingle.

While the coating material is still soft and plastic the strips l and 3, and 2 and t pass under crushed slate hoppers 3t and 38 which shower crushed slate or other wear-resisting material upon the coated portion 3|] of the strips. As showm in Fig. 1, the strips also pass over the rolls' M which press the crushed slate into the plastic coating 30. The strips are then conducted over the cooling rolls a2 and over the timing rolls t3, projections upon the periphery of which engage in the notches between the tabs upon the strips. The cutters it are so synchronized with the timing rolls 33 that the strips are out along a line of severance between the proper tabs to form the finished shingle strips or elements 50, a section of which is shown in Fig. 5. From Fig. 5 it will be noted that the element involves a felted fibrous foundation 5i which may be and preferably is the usual roofing felt. This felt, as hereinabove described, is saturated with bituminous material and then completely coated with bituminous material as indicated at 52. If desired, the asphalt coating on the base of the felted foundation may be rendered non-cementi tious'by dusting it with mica, forming a. seal back coating 53 for the element. A layer of granular material it partially embedded over the complete face of .the bituminous coating 52;

then applied to thegranular surfacing 55 so that it extendsover the top tabportions of the ele-- m'ent, covering the lower exposed face or tab portion and leaving uncoated the top portion of the element. This second coating is extended about the cut edges of the tabs, thus sealing the edges' The second coating, it .will be noted, does not cover the base portion of the element, but

covers only part of the top and side edges the1'e of. Granular material 51 is thenpartially embedded in the bituminous coatings 56.

.of substantially uniform thickness extending from the forwardedge of said element and substantially completely covering the granular material on the lower portion only of the face of said element to be exposed to the weather, said second layer of 'coating material being extended about the forward and side edges of the element ,A second coating 56 of. bituminous material is but not upon the back of the elem'ent,thus seal-,

ing the cut edges of the element, a second layer of granulanmaterial partially embedded in the second layer of coating material, and the back of said saturated, fibrous foundation having thereon only a single layer of coating material covered with non-cementitious material.

2. A thick butt shingle strip having tabs along the longitudinal edge of the body portion adapted to be exposed to the weather when laid, consisting of a saturated fibrous foundation, a layer of waterproof coating material of substantially uniform thickness completely covering the face of said foundation, a layer of granular material partially embedded'in said layer of coating material and substantially completely covering the face of said foundation, a second layer of coating material of substantially uniform thickness extending from the forward-tab edges-of said strip and substantially completely covering the granular material on the lower portions only of the-face of said strip to be exposed to the weather,said second layer of coating material being extended about the forward and side edges of the tabs of the strip but not upon the'back of the strip, thus sealing the cut edges of thetabs, a second layer of granular material partially em-,- bedded in the second layer of coating material, and the back of said saturated fibrous foundation having thereon only coating material of uniform thickness covered with non-cementitious material.

CLARENCE R. ECKERT. 

